A precision coating system and method for flammable and explosive workpieces

Abstract

The application discloses a kind of flammable and explosive workpiece precision coating system and method, comprising: eigenvalue identification system, host computer;The eigenvalue identification system includes: 2D visual identification system, 3D visual identification system, laser distance sensor, 2D visual identification system, 3D visual identification system, laser distance sensor, respectively integrated on spherical spraying robot;2D visual identification system is used for the feature identification of workpiece's spraying position, spraying angle, accurately provides the starting value of robot movement, guides robot movement;3D visual identification system is used for the feature identification of workpiece's front / back surface and levelness, accurately determines robot movement program number and eccentricity;Laser distance sensor is used for levelness feature identification.

Description

Technical Field

[0001] This invention relates to the fields of control technology and software technology, and more specifically to a precision coating system and method for flammable and explosive workpieces. Background Technology

[0002] Robots are often used when coating flammable and explosive workpieces. There is a risk that the robot may collide with the flammable and explosive workpieces, leading to a fire or explosion. Summary of the Invention

[0003] The purpose of this invention is to provide a precision coating system and method for flammable and explosive workpieces, in order to solve the technical problems in the background art.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A precision coating system for flammable and explosive workpieces includes: a feature value recognition system and a main unit;

[0006] The feature recognition system includes a 2D vision recognition system, a 3D vision recognition system, and a laser distance sensor, which are integrated onto the spherical spraying robot. The 2D vision recognition system is used for feature recognition of the spraying position and angle of the workpiece, accurately providing the robot's starting value and guiding its movement. The 3D vision recognition system is used for feature recognition of the front / back surface and levelness of the workpiece, accurately determining the robot's motion program number and ensuring it is not eccentric. The laser distance sensor is used for levelness feature recognition.

[0007] The host system includes: a main control PLC for the spherical spraying robot, a process PLC, and a server;

[0008] The spherical spraying robot, 2D vision recognition system, and 3D vision recognition system communicate with the process PLC via Profinet; the laser sensor outputs a (4-20) mA analog signal to the AI ​​module of the process PLC; the process PLC communicates with the main control PLC via Profinet; and the main control PLC communicates with the main control server via TCP / IP.

[0009] A precision coating method for flammable and explosive workpieces includes the following steps:

[0010] The method of identifying the front / back side and levelness features is used to determine whether the workpiece has been successfully mounted.

[0011] The spraying position and angle of the workpiece are identified by using the spraying position and angle feature recognition method;

[0012] Triple identification of the levelness of the workpiece during the spraying process.

[0013] In some embodiments, the method for determining whether a workpiece has been successfully mounted using front / back surface and levelness feature recognition includes:

[0014] (1) When loading the workpiece, manually input the workpiece's orientation and adjust its levelness;

[0015] (2) The 3D vision recognition system automatically identifies the workpiece and detects the front and back status and level of the workpiece. If the detected front and back status is consistent with the front and back information input manually and the level meets the requirements, the PLC judges that the loading is successful and releases the flammable and explosive workpiece to the spraying station; otherwise, the loading is unsuccessful, an alarm is triggered and manual processing is required.

[0016] In some embodiments, the 3D vision recognition system automatically identifies the workpiece and detects its front / back state and levelness; including: importing the actual front / back model of the workpiece into the system to generate a calibration file; configuring 8 points on the contour lines of the circumference according to the actual diameter and size of the workpiece to accurately characterize the levelness of the workpiece; setting upper and lower limits for the horizontal height difference to identify the levelness of the workpiece.

[0017] In some embodiments, the method of identifying the spraying position and angle of the workpiece using the spraying position and angle feature recognition method includes: target feature recognition and positioning using a combination of initial positioning and fine positioning. First, a 2D vision recognition system is used to take a high-level photo of the workpiece, identify the template reference angle, X and Y values, and compare them with the template. If they match, they are compared with the reference angle, and the angle value is sent to the robot. Then, a 2D vision recognition system is used to take a low-level photo, take a photo, and determine whether it matches the template. If it matches the template, it is compared with the reference position, and the X and Y deviations are sent to the robot.

[0018] In some embodiments, the triple leveling of the workpiece during the spraying process includes: after the workpiece arrives at the spraying station from the loading station, a leveling verification procedure is performed; if the verification passes, the workpiece is lifted, and a leveling verification procedure is performed again before the spraying operation; if the verification passes, spraying is carried out; after the spraying operation is completed and the conditions for release are met, a leveling verification procedure is performed a third time; if the verification passes, the workpiece is released to the next station; during the triple leveling process, if the leveling verification fails, an alarm is triggered and the movement is stopped, awaiting further processing.

[0019] The beneficial effects of this invention compared to the prior art are:

[0020] The purpose of this invention is to provide a method and safety control for identifying the characteristic values ​​of flammable and explosive workpieces during precision coating. It integrates a 2D smart camera, a 3D smart camera, and a laser distance sensor onto a robot, communicating and interacting with the robot and the main control PLC to accurately identify the workpiece's special characteristic values, such as spraying position, spraying angle, front / back of the product, and levelness. This guides the robot's spraying position and angle, ensuring the quality and consistency of the precision coating, and preventing the robot from colliding with flammable and explosive workpieces to avoid explosions. The levelness of the flammable and explosive workpiece is a safety guarantee against misalignment; triple identification of this levelness prevents the workpiece from falling during the spraying process and causing an explosion. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the communication between the feature value recognition system and the host computer;

[0022] Figure 2 This is a schematic diagram of the front / back and horizontality feature recognition method;

[0023] Figure 3 This is a schematic diagram of a method for identifying the position and angle features of spherical spray coating;

[0024] Figure 4 This is a schematic diagram of the level-based triple recognition method. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are some, but not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0026] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0028] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0029] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or display that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or display.

[0030] The following will combine Figures 1-4 This application provides a detailed description of a precision coating system and method for flammable and explosive workpieces, as described in the embodiments of this application. It is worth noting that the following embodiments are merely illustrative of this application and do not constitute a limitation thereof.

[0031] Example 1:

[0032] See Figures 1-4 As shown, a precision coating system for flammable and explosive workpieces includes: a feature value recognition system and a host computer;

[0033] The feature recognition system includes a 2D vision recognition system, a 3D vision recognition system, and a laser distance sensor, all integrated onto the spherical spraying robot. The 2D vision recognition system identifies the spraying position and angle of the workpiece, accurately providing the robot's initial motion values ​​and guiding its movement. The 3D vision recognition system identifies the front / back surfaces and levelness of the workpiece, accurately determining the robot's motion program number and preventing eccentricity, thus avoiding collisions with flammable or explosive workpieces, preventing workpiece eccentric falls, and avoiding damage, combustion, and explosions. The laser distance sensor is the second method for levelness feature recognition.

[0034] The main unit includes: the main control PLC for the spherical spraying robot, the process PLC, and the server.

[0035] The feature value recognition system communicates with the host computer. Figure 1 The robot and vision recognition system communicate with the process PLC via Profinet. A laser sensor outputs a (4~20) mA analog signal to the AI ​​module of the process PLC. The process PLC communicates with the main control PLC via Profinet. The main control PLC communicates with the main control server via TCP / IP.

[0036] A precision coating method for flammable and explosive workpieces includes the following steps:

[0037] The method of identifying the front / back side and levelness features is used to determine whether the workpiece has been successfully mounted.

[0038] The spraying position and angle of the workpiece are identified by using the spraying position and angle feature recognition method;

[0039] Triple identification of the levelness of the workpiece during the spraying process.

[0040] Front / back and levelness feature recognition methods

[0041] The front / back state of flammable and explosive workpieces directly determines the programs called by robots and inkjet printers. Errors in front / back information will cause collisions between the robot / inkjet printer and the workpiece, resulting in workpiece damage, combustion, and explosion.

[0042] If the workpiece levelness does not meet the requirements, it will cause the flammable and explosive workpiece to become eccentric when rotating, which will cause the flammable and explosive workpiece to fall, resulting in damage, combustion and explosion of the flammable and explosive workpiece.

[0043] The front / back and levelness features are identified using a vision recognition system, which automatically identifies the front / back and levelness of the workpiece to ensure that the front / back status and levelness of the workpiece are accurate.

[0044] (1) When loading the workpiece, manually input the workpiece's orientation and adjust its levelness;

[0045] (2) The visual system automatically identifies the workpiece, detecting its front and back positions and levelness. If the detected front and back positions match the manually input information and the levelness meets the requirements, the PLC determines that the workpiece loading is successful and releases the flammable and explosive workpiece to the spraying station. Otherwise, the workpiece loading fails, an alarm is triggered, and manual intervention is required.

[0046] For front / back and levelness feature recognition methods, see Figure 2 The system imports the actual front / back model of the workpiece and generates a calibration file. Based on the workpiece's actual diameter and dimensions, eight points are configured on the contour lines of the circumference to accurately characterize the workpiece's levelness. Upper and lower limits for the horizontal height difference are set to identify the workpiece's levelness.

[0047] Spraying position and angle feature identification method

[0048] The vision recognition system is integrated into the spherical spraying robot arm. The spraying position and angle feature recognition is used to identify the spraying position and angle, accurately providing the starting values ​​for the spherical spraying robot's movement and guiding the robot's motion.

[0049] Target feature recognition and positioning employs a combination of initial and fine positioning methods, utilizing both high-level and low-level photography. First, a 2D vision recognition system is used to take a high-level photograph of the workpiece, identifying the template's reference angle and X and Y values. This is compared to the template; if a match is found, the angle is compared to the reference angle, and the obtained angle value is sent to the robot. Then, a low-level photograph is taken using the 2D vision recognition system. The photograph is then compared to the template; if a match is found, the X and Y deviations are compared to the reference position and sent to the robot. For the method of identifying the position and angle features of spherical spraying, see [link to documentation]. Figure 3 .

[0050] Triple recognition of level

[0051] The spraying process includes automatic workpiece conveying to the spraying station, lifting after arrival, rotation after lifting, and spraying during rotation. Because the workpiece may tilt due to vibration, rotation, or other factors during automatic conveying, lifting, and rotation, its levelness may not meet requirements, leading to eccentricity during rotation and potentially causing it to fall. Therefore, levelness is assessed three times during the spraying operation: after arrival, before operation, and before release. A laser distance sensor is integrated into the robot, and the robot's motion trajectory software calls a levelness verification program to determine whether the levelness of flammable and explosive workpieces meets requirements.

[0052] After the workpiece arrives at the spraying station from the loading station, a levelness check procedure is performed. If the check passes, the workpiece is lifted, and a levelness check procedure is performed again before spraying. If this check also passes, spraying can proceed. Once spraying is completed and the workpiece is ready for release, a third levelness check procedure is performed. If this check passes, the workpiece is released to the next station. During this triple-check process, if the levelness check fails, an alarm is triggered, and movement is stopped pending further action. See the triple-check method for levelness. Figure 4 .

[0053] The above description is merely a preferred embodiment of the present invention and is intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A precision coating method for flammable and explosive workpieces, implemented through a coating system, characterized in that, The coating system includes: a feature value recognition system and a host computer; The feature recognition system includes a 2D vision recognition system, a 3D vision recognition system, and a laser distance sensor, which are integrated onto the spherical spraying robot. The 2D vision recognition system is used for feature recognition of the spraying position and angle of the workpiece, accurately providing the robot's starting value and guiding its movement. The 3D vision recognition system is used for feature recognition of the front / back surface and levelness of the workpiece, accurately determining the robot's motion program number and ensuring it is not eccentric. The laser distance sensor is used for levelness feature recognition. The host system includes: a main control PLC for the spherical spraying robot, a process PLC, and a server; The coating method includes the following steps: A 3D vision recognition system is used to identify the front / back and horizontality features of a workpiece to determine whether the workpiece has been successfully mounted. A method for identifying the spraying position and angle of a workpiece is used, employing a 2D vision recognition system. The workpiece undergoes a triple leveling check during the spraying process. This triple check includes: after the workpiece arrives at the spraying station from the loading station, a leveling check procedure is executed; if the check passes, the workpiece is lifted, and a second leveling check procedure is executed before spraying; if this check also passes, spraying begins; after spraying is completed and conditions for release are met, a third leveling check procedure is executed; if this check passes, the workpiece is released to the next station. During the triple check, if the leveling check fails, an alarm is triggered and movement is stopped, awaiting further processing.

2. The precision coating method for flammable and explosive workpieces according to claim 1, characterized in that, The method for determining whether a workpiece has been successfully mounted using front / back surface and levelness feature recognition includes: (1) When loading the workpiece, manually input the workpiece's orientation and adjust its levelness; (2) The 3D vision recognition system automatically identifies the workpiece and detects the front and back status and level of the workpiece. If the detected front and back status is consistent with the front and back information input manually and the level meets the requirements, the PLC judges that the loading is successful and releases the flammable and explosive workpiece to the spraying station; otherwise, the loading is unsuccessful, an alarm is triggered and manual processing is required.

3. The precision coating method for flammable and explosive workpieces according to claim 2, characterized in that, The 3D vision recognition system automatically identifies the workpiece, detecting its front / back state and levelness; including: importing the actual front / back model of the workpiece into the system to generate a calibration file; configuring 8 points on the contour lines of the circumference based on the actual diameter and size of the workpiece to accurately characterize the workpiece's levelness; and setting upper and lower limits for the horizontal height difference to identify the workpiece's levelness.

4. The precision coating method for flammable and explosive workpieces according to claim 2, characterized in that, The method for identifying the spraying position and angle of a workpiece using spraying position and angle features includes: target feature identification and positioning using a combination of initial positioning and fine positioning. First, a 2D vision recognition system is used to take a high-level photo of the workpiece, identify the template reference angle, X and Y values, and compare them with the template. If they match, the angle value is compared with the reference angle and sent to the robot. Then, a 2D vision recognition system is used to take a low-level photo, and the photo is taken to determine whether it matches the template. If it matches the template, the X and Y deviations are compared with the reference position and sent to the robot.

5. A precision coating system for flammable and explosive workpieces, used to implement the precision coating method for flammable and explosive workpieces as described in any one of claims 1-4, characterized in that, The spherical spraying robot, 2D vision recognition system, and 3D vision recognition system communicate with the process PLC via Profinet; the laser sensor outputs a (4-20) mA analog signal to the AI ​​module of the process PLC; the process PLC communicates with the main control PLC via Profinet; and the main control PLC communicates with the main control server via TCP / IP.

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